If this is your first visit, be sure to
check out the FAQ by clicking the
link above. You may have to register
before you can post: click the register link above to proceed. To start viewing messages,
select the forum that you want to visit from the selection below.

Millermatic 200 no welding current

07-18-2014, 01:15 PM

NOW FIXED! See last post

Hi, while welding, suddenly I was not able to get an arc. I can get a small sparks on both low and high voltage settings, but no current. Also, the Transformer hum slowly goes away when trying to strike.

Someone else had the same problem in 2011, although his solution was a gun fault ... this doesn't seem to be that. I did do the drive to ground check recommended in that post, and I get 15-16v (low voltage) setting when operating the gun and striking the arc (reading does not change when striking). Same on the high setting except voltage is 29+ volts.

Feed motor runs, the contactor closes, and gas valve opens.

It is a really old unit, and I cannot find a serial number. I have posted a photo in case it helps!

Comment

Open it up, likely have a busted winding going to your output studs. Just have to yank on it, drill it and stuff it back on, unless it damaged the output stud, in which case you can get another, or Magiver it.

Comment

Checked the voltage from the welding wire exiting the gun to ground, shows 29V.

I vaguely remember that the gun felt hot after I stopped welding, prior to it not working, so took the gun apart ... It looked like the insulation had melted and only a couple of the braided wires were attached (see last image below).

Any suggestions on how to re-attached the wires? Do I clean everything up, feed them through the rearmost collar, and then tighten the collar onto the nozzle?

Photos attached ....

Comment

Checked the voltage from the welding wire exiting the gun to ground, shows 29V.

I vaguely remember that the gun felt hot after I stopped welding, prior to it not working, so took the gun apart ... It looked like the insulation had melted and only a couple of the braided wires were attached (see last image below).

Any suggestions on how to re-attached the wires? Do I clean everything up, feed them through the rearmost collar, and then tighten the collar onto the nozzle?